Industrial Machine Data Bus Protocol With Manager-Worker Switching
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Solution Overview
Problem
Existing methods for collecting and communicating machine data from industrial machines require manual human intervention, which is time-consuming and inefficient, and existing communication technologies face challenges such as limited wireless communication, noise interference, and non-standardized protocols.
Innovation Solution
A system of data extraction and communication (DEC) modules that utilize transceivers and interlocking connectors, enabling communication via half-duplex, full-duplex, and extended modes, with a multi-manager token line to manage data transfer, allowing efficient data collection and transmission to a monitoring and maintenance platform using standardized protocols.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If manual human intervention is used to collect and communicate machine data, then data collection can be performed with simple hardware, but the process becomes time-consuming and inefficient
Solution Approach 1:
The system enables machines to automatically collect and transmit their own operational data through integrated sensors and communication modules, eliminating the need for manual data collection by operators. The automated DEC modules continuously monitor machine parameters and communicate data to the platform without human intervention.
Solution Approach 2:
The patent replaces manual mechanical data collection methods with electronic sensor-based systems and wireless communication technologies. Sensors automatically detect machine parameters and transmit data electronically, substituting the mechanical process of manual measurement and recording.
2Adaptability or versatility
If wireless communication is used for data transmission, then mobility and flexibility are improved, but communication reliability deteriorates due to limited range and noise interference
Solution Approach 1:
The system introduces wired communication infrastructure (Ethernet cables, network switches) as intermediaries between machines and the central platform. This hybrid approach maintains the flexibility of wireless sensors at the machine level while using reliable wired connections for data transmission, thereby preserving adaptability while improving reliability.
Solution Approach 2:
The communication system is segmented into two parts: wireless sensor nodes at the machine level that provide flexibility and mobility, and wired network infrastructure that ensures reliable data transmission. This segmentation allows each layer to optimize for its specific function.
3Adaptability or versatility
If standardized communication protocols are implemented across all devices, then system interoperability and ease of integration are improved, but device complexity increases due to protocol implementation requirements
Solution Approach 1:
The system adopts a universal communication protocol (Modbus RTU over RS485) that can be implemented across all DEC modules and the central platform. This single standardized protocol serves multiple functions: data collection, transmission, and processing, simplifying the overall system architecture while maintaining interoperability.
Solution Approach 2:
The system uses configurable communication parameters (baud rate, data bits, stop bits, parity) that can be adjusted to match different device requirements while maintaining the same protocol framework. This allows flexibility in implementation without requiring multiple different protocols.
4Adaptability or versatility
If multiple devices communicate simultaneously on the same communication lines, then device quantity and system scalability are improved, but communication reliability deteriorates due to potential conflicts and interference
Solution Approach 1:
The system implements periodic data transmission where each device transmits data at scheduled intervals rather than continuously or simultaneously. The central controller polls devices in a predetermined sequence, ensuring that communication occurs in organized time slots, which prevents conflicts while maintaining scalability.
Solution Approach 2:
The communication protocol includes acknowledgment mechanisms where the central controller receives data from devices and sends confirmation signals. This feedback loop ensures that each transmission is successfully received and processed, maintaining reliability even as the number of devices increases.
Data Source
AI summary
Devices, such as sensors, can interface with industrial machines and/or the industrial machine computers or sensors, and can extract or obtain machine operation data. Devices can communicate the machine data, via a communication bus, using hardware and software-based communication protocol. Efficiencies can be realized when the devices share the same communication bus and can communicate with one another, by assuming manager or worker status. The devices can include transceivers, having drivers and receivers. In some embodiments, the communication lines can include a talk like and an answer line, connecting all the devices. The devices can selectively connect to the talk line to assume the role of a manager, or connect to the answer line to assume the role of a worker.